集成IIoT设备

Integrating IIoT equipment

Industrial Internet of Things (IIoT) equipment should be integrated even into older manufacturing systems to optimize facility and system operations. Think you’re using IIoT technologies? Are you adding sensors in 12 steps or 6 steps?

The Industrial Internet of Things (IIoT) has been brought up in the media, and many mainstream instrumentation and controls vendors even remarket their existing product lines as IIoT products. Engineers often suggest they’ve “been doing IIoT for years.” However, there is a lack of understanding around IIoT. What the industry has been doing often differs from what IIoT promises. Just like calling a goose a duck, it’s incorrect.
Yes, the sensors used in manufacturing are becoming smarter and better connected. Yes, they are coming with onboard web configuration interfaces, but are they really IIoT? What does the process of implementing additional sensors into manufacturing systems using traditional methods look like?
Adding sensors in 12 steps
For example, if a proximity switch was going to be added to a manufacturing line to count the number of units produced, the process would include the following steps:
1. Identify the need
2. Define requirements and specify hardware and cabling
3. Identify an open contact on a digital input module or add an expensive high-speed counting module, depending on speed requirements and engineering in step one
4. Purchase the sensor
5. Mechanically install the proximity switch
6. Wait for downtime on production systems
7. Add a new module to the programmable logic controller (PLC) rack, if needed
8. Run wire from the proximity switch to the input module
9. Modify the PLC program to execute logic based on the new functionality to count pulses and identify when the counter will roll over to avoid an overflow situation 

10. Test the PLC program logic
11. Create a human-machine interface (HMI) display to use production counts, or configure a historian to log production counts
12. Optionally, take additional steps to tie the new counter into higher level manufacturing execution system (MES)/line performance system to capture overall equipment effectiveness (OEE).
To add one sensor and leverage the information it provides, writing the PLC code, and building the appropriate applications require a significant time and money investment. This becomes even more challenging if the equipment is aging and doesn’t currently have a PLC, as there are still mechanical manufacturing lines operating today. For example, a few years back, a pie shell machine was in operation and was comprised entirely of motors, gears, pulleys, and relays—not one PLC. Don’t assume that because the system is old, the need to gather smart data metrics diminishes. Many vendors would recommend adding a PLC to this system to gather critical production metrics—requiring designing a control panel, electrical wiring, and buying a PLC with an input/output (I/O).
Adding sensors in 6 steps
Now, let’s compare this process with a modern IIoT implementation process:
1. Identify the need
2. Purchase the IIoT device and sensor
3. Mechanically install the proximity switch
4. Connect the IIoT device to a wireless network, hardwired ethernet, or purchase the IIoT device with onboard 2G/3G connectivity already activated
5. Plug into 120 V or 24 Vdc power
6. Create an account in the cloud web application.
Done. No engineering. No coding. Just plug-and-play. Personnel can walk down to the plant floor from the boardroom and have a wealth of collected data within an hour. Data may include being able to count parts, display and trend, downtime metrics. Added capabilities may include access to downtime metrics, mean time between failures (MTBF), mean time to repair (MTTR), OEE, and other analytics. For example, if a worker were to place an internet browser window near the line, stop causes would be received that were selected by a prepopulated list from the operator, allowing the worker to analyze production stoppages.
The total cost for this would be approximately $150 per month, per sensor, with unlimited users—a cost that would report a big return on investment.
IIoT acceleration
As a system integrator, this could be quite unnerving. There has been gradual shift from original equipment manufacturers (OEM) vendors to minimize the friction for implementing their products and lower the total cost of implementation by reducing the labor of system integration.
So why is IIoT a game changer? For example, at a house, each floor may have its own HVAC unit, totaling three unique systems that operate independent of each other. These systems have no onboard Ethernet or wireless connectivity. Like many machines and systems existing on plant floors, they’re disconnected and self-contained operational units. By connecting smart thermostats, in less than an hour, all three units were connected to the internet and operating together. To turn the heat on, all units can be switched to that mode through a mobile device. A central supervisory control and data acquisition (SCADA) system
can offer control and monitoring capabilities, and the units no longer operate independently. Built-in analytics and smart control features are included saving money and increasing operational efficiency.
Smarter, faster systems
This is the true power of IIoT—making existing systems smarter, without a rip-and-replace.
This is the future of manufacturing—purpose-built applications with a mixture of computing and control at the edge, connected to cloud-based applications with ready-to-go analytics.
Many manufacturers were left behind during the Industry 3.0 movement while others are in states of “islands of automation” with disconnected assets. In many cases, moving from disconnected production assets to enterprise connected assets with traditional engineering could mean either a complete re-control or rip-and-replace. This requires huge capital investment for systems that may still be functioning profitably. The need for data to drive decisions is increasing.
IIoT allows manufacturers to smart-enable their assets to potentially save thousands in operational expenditure funding, and tens of millions of dollars in capital expenditure funding. IIoT means smarter production systems now, with minimal investment costs. 

To move up the digitization continuum can be cost prohibitive, until now. IIoT helps any organization capture critical data using low-cost edge devices, skipping layers at relatively little cost. Courtesy: Avid Solutions

工业物联网（IIoT）设备甚至应集成到较旧的制造系统中，以优化设施和系统操作。认为你正在使用IIoT技术？您是以12步或6步添加传感器吗？

工业物联网（IIoT）已经在媒体上出现，许多主流仪器和控制供应商甚至将其现有的产品线作为IIoT产品进行再销售。工程师经常建议他们“多年来一直在做IIoT。”然而，对于IIoT缺乏了解。该行业一直在做的事情往往与IIoT承诺的不同。就像把鹅叫做鸭子一样，这是不正确的。
是的，制造业中使用的传感器变得越来越智能，连接性也越来越好。是的，它们带有板载Web配置界面，但它们真的是IIoT吗？使用传统方法将额外传感器实施到制造系统中的过程如何？
以12个步骤添加传感器
例如，如果要将接近开关添加到生产线以计算生产的单元数，则该过程将包括以下步骤：
1.确定需求
2.定义要求并指定硬件和布线
3.识别数字输入模块上的开路触点或添加昂贵的高速计数模块，具体取决于步骤1中的速度要求和工程
4.购买传感器
5.机械安装接近开关
6.等待生产系统停机
7.如果需要，将新模块添加到可编程逻辑控制器（PLC）机架
8.将接线开关的导线连接到输入模块
9.修改PLC程序以基于新功能执行逻辑以计数脉冲并识别计数器何时翻转以避免溢出情况

10.测试PLC程序逻辑
11.创建人机界面（HMI）显示以使用生产计数，或配置历史记录以记录生产计数
12.可选地，采取额外步骤将新计数器连接到更高级别的制造执行系统（MES）/线路性能系统，以捕获整体设备效率（OEE）。
要添加一个传感器并利用它提供的信息，编写PLC代码以及构建适当的应用程序需要大量的时间和金钱投入。如果设备老化并且目前没有PLC，这将变得更具挑战性，因为目前仍有机械生产线运行。例如，几年前，一台馅饼壳机器正在运行，它完全由电机，齿轮，皮带轮和继电器组成 - 而不是一台PLC。不要认为因为系统已经过时，收集智能数据指标的需求会减少。许多供应商会建议在该系统中添加PLC以收集关键的生产指标 - 需要设计控制面板，电线和购买带输入/输出（I / O）的PLC。
通过6个步骤添加传感器
现在，让我们将这个过程与现代IIoT实现过程进行比较：
1.确定需求
2.购买IIoT设备和传感器
3.机械安装接近开关
4.将IIoT设备连接到无线网络，硬连线以太网，或购买已**板载2G / 3G连接的IIoT设备
5.插入120 V或24 Vdc电源
6.在云Web应用程序中创建一个帐户。
完成。没有工程。没有编码。即插即用。人员可以从会议室走到工厂的楼层，并在一小时内收集到大量的数据。数据可能包括能够计算零件，显示和趋势，停机时间指标。增加的功能可能包括访问停机时间指标，平均故障间隔时间（MTBF），平均修复时间（MTTR），OEE和其他分析。例如，如果工作人员要在线路附近放置互联网浏览器窗口，则会收到由运营商预先填充的列表选择的停止原因，允许工作人员分析生产停工。
对于每个传感器，每个传感器的总成本约为150美元，用户数量不受限制 - 这一成本将带来巨大的投资回报。
IIoT加速
作为系统集成商，这可能会非常令人不安。原始设备制造商（OEM）供应商逐渐转向最小化实施其产品的摩擦，并通过减少系统集成的劳动力来降低实施的总成本。

那么为什么IIoT会改变游戏规则呢？例如，在一个房屋中，每个楼层可以具有其自己的HVAC单元，总共三个独立的系统彼此独立地操作。这些系统没有板载以太网或无线连接。与工厂车间中存在的许多机器和系统一样，它们是断开连接的和独立的操作单元。通过连接智能恒温器，在不到一个小时的时间内，所有三个单元都连接到互联网并一起运行。要打开热源，可以通过移动设备将所有设备切换到该模式。*监督控制和数据采集（SCADA）系统
可以提供控制和监控功能，并且这些单元不再独立运行。内置分析和智能控制功能可节省资金并提高运营效率。
更智能，更快速的系统
这是IIoT的真正力量 - 使现有系统更加智能，无需拆除。
这是制造专用应用程序的未来，它将边缘的计算和控制混合在一起，通过随时可用的分析连接到基于云的应用程序。
许多制造商在工业3.0运动期间落后，而其他制造商处于“自动化孤岛”状态，资产断开。在许多情况下，使用传统工程从断开连接的生产资产转移到企业连接资产可能意味着要么完全重新控制，要么进行重新替换。这需要对可能仍在盈利的系统进行大量资本投资。数据推动决策的需求正在增加。
IIoT允许制造商智能化其资产，可以节省数千美元的运营支出资金，以及数千万美元的资本支出资金。 IIoT意味着现在更智能的生产系统，投资成本最低。

到目前为止，向上移动数字化连续体可能成本过高。 IIoT可帮助任何组织使用低成本边缘设备捕获关键数据，以相对较低的成本跳过层。礼貌：Avid解决方案